Th is manual is intended only for use by a qualifi ed heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these
instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction.
the burner, resulting in possible severe personal injury, death or substantial property damage. Th e boiler can only be operated with a dust-
free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated by operation
with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
Affi x these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualifi ed service technician,
and to follow all guidelines in the User' s Information Manual.
Finned copper tube
Gas boilers (MB) &
Water heaters (MW)
Boiler manual
Installation and operation
instructions
Also read and follow:
XLF HeatNet Control manual
Construction dust and particulate, particularly drywall dust, will cause contamination of
Spectrum finned copper gas boilers & water heaters (32 pages)
Summary of Contents for RBI FUTERA XLF Series
Page 1
XLF-I0M-2 82-0317 Finned copper tube Gas boilers (MB) & Water heaters (MW) Boiler manual Installation and operation instructions Also read and follow: XLF HeatNet Control manual Th is manual is intended only for use by a qualifi ed heating installer/technician. Read and follow this manual, all supplements and related instructional information provided with the boiler.
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Futera -Series boilers — Overview XLF PRIMARY COMPONENTS Electrical enclosure (rear) Blower and motor Air inlet connection Flue outlet connection Gas entrance Boiler water return Boiler water supply Gas valve Power entrance box...
This manual covers the application, installation, operation and BOILER/WATER HEATER LOCATION ... . 4 maintenance of a Futera XLF Series fi nned copper heating boiler/ water heater/pool heater. COMBUSTION AIR & VENTILATION ... . . 4 To obtain the safe, dependable, efficient operation and long life GENERAL VENTING GUIDELINES.
RATINGS & CAPACITIES that would subject it to temperatures at or near freezing, Before undertaking the installation of the Futera XLF Series boiler/ see the “FREEZE PROTECTION” section on page 14. water heater check the rating plate to ensure that the unit has been sized Never store combustible materials, gasoline or any properly for the job.
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M All air from inside the building Table 2 Make-up Air Louver Sizing If the Futera XLF is to be located in a confi ned space, the minimum Input Required cross-sectional area clearances listed in Table 1, page 4 must be maintained between it...
3 ft , 0.9 m intervals with overhead hangers. boiler installation. Close fi replace dampers. Th e certifi ed intake air terminal from RBI must be used, see Figure 1, 4. Place in operation the appliance being inspected. Follow the page 8, Figure 2, page 8 and Figure 4, page 9.
UL 1738 for installations in the United States, ULC S636 for installations in Canada. Th e certifi ed vent terminal from Combination direct vent systems RBI must also be used. Figure 4 (vent/air pipe equivalent lengths up to100 feet maximum) Th e maximum equivalent length for the horizontal vent pipe is 100 ft ,...
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Figure 1 VENT OPTION 1: DIRECT VENT — Horizontal air intake and venting for a single direct vent system Vent pipe and air pipe equivalent lengths must not exceed 100 feet each. See Table 3 or 4 for min. pipe diameters. W hen running horizontal combustion air and venting for single or multiple units, exhaust and combustion air terminals must...
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Figure 4 VENT OPTION 1: DIRECT VENT — Vertical air intake and venting for direct vent system Vent pipe and air pipe equivalent lengths must not exceed 100 feet each. See Table 3 or 4 for min. pipe diameters. Locate exhaust terminal from air intake downwind...
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M lined and sized. Exterior masonry chimneys should not be used OPTION 2: VERTICAL VENTING unless properly lined to prevent condensation and draft problems. POSITIVE PRESSURE, CATEGORY IV Table 4 lists the equivalent breeching and fl ue sizes required for the boiler/water heater.
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M OPTION 3: SIDE WALL VENTING POSITIVE PRESSURE —CATEGORY IV FIGURE 7 “Combustion Air & Ventilation” section must be followed! Th e vent (VENT/AIR PIPE EQUIVALENT LENGTHS UP TO 100 FEET MAXIMUM) guidelines under the Horizontal Direct Vent Systems section must In this configuration the boiler/water heater blower is used also be followed.
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M OPTION 4: VERTICAL CHIMNEY VENTING CATEGORY II CHIMNEY NEGATIVE PRESSURE — CATEGORY II INSPECTION & SIZING (MULTIPLE BOILERS WITH COMMON VENTING) Masonry chimneys, when used, must be lined with a metal liner certifi ed for Category IV venting.
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Figure 8 OPTION 4: VERTICAL CHIMNEY VENTING — Vertical venting — multiple-boiler installations See Table 5, page 12 for minimum riser diameter (dimension F) DO NOT common vent more than the following number of Futera XLF boilers: XLF-2500/3000 (4) boilers maximum.
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M GENERAL PIPING REQUIREMENTS Flow Switch Th e fl ow switch supplied with the boiler/water heater must be wired to the terminal strip in the control panel to prevent the boiler from Improper piping of this boiler/water heater will void fi ring unless there’...
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M A temperature rise outside of the range listed in Table 7 Th e maximum allowable fl ow rate through a Futera will result in damage to the heat exchanger, voiding the XLF boiler is 260 GPM, 16.4 L/s when equipped with warranty! Th e maximum allowable temperature rise copper tubes.
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Primary/secondary piping Table 7 Temperature Rise Table Boilers connected to heating systems using zone valves, zone pumps, Model ΔT = 20 ΔT = 11.1 or systems that have excessive fl ow rates or return water temperatures Number Flow Rate Pres.
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Figure 10 Typical Primary/Secondary Piping System (See Notes) NOTES: 1. Boiler circuit piping must be sized large enough to handle maximum fl ow through unit. 2.
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Figure 12 Low Temperature Piping (See Notes and Adjustment Procedures) H-3 Rev 5 Figure 13 Multiple Boiler Piping (See notes) These drawings show suggested piping con- fi guration and valving.
C will provide an increased quantity of 315 GPM, 19.9 L/s. See Table 9, page 20. tempered water and help prevent the growth of RBI water heaters are designed to run scale free. Due to water born bacteria. the extreme variables of water conditions world wide it is necessary to consider pH values and water hardness in relationship to scaling.
In some areas of the country additional precautions must be observed due to unusual characteristics of the local water supply. Call the nearest RBI representative for details. To properly size the pump a grain hardness and pH test must be taken at the installation site before the order is placed.
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Figure 14 Typical Water Heating Piping (MW Models Only) (See Notes) Th ese drawings show sug- gested piping confi guration and valving. Check with local codes and ordinances for specifi c requirements.
Th e Futera XLF comes from the factory ready to be piped to the gas supply. If for any reason the boiler/water heater is not for the type of gas available at the installation site, call your RBI representative to resolve the problem.
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M ELECTRICAL WIRING Table 11 Equivalent length (feet) for typical fi ttings Electrical power connections Pipe Fitting or valve size Label all wires prior to disconnection when servicing elbow Gate (branch fl ow)
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M GENERAL OPERATION WIRING & CONTROL SET-UP Before proceeding read and fully understand the instructions contained in this manual. Do not att empt Follow the instructions in the Futera XLF Control to operate this boiler/water heater if it has not been installation and operation instruction manual installed in accordance with the guidelines set forth in...
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M SEQUENCE OF OPERATION Figure 17 HeatNet Control Panel NO DEMAND Standby 1. Th e boiler is idle with no interlocks in the fault condition. DEMAND Pre-Purge 1.
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M b. Connect one side of a manometer or pressure gauge to the The following start-up procedure assumes that all water piping, gas piping and electrical connections manometer pressure port (barbed) on the pressure test manifold (located inside control panel).
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Leave the manometer connected to the test manifold. Verify low fi re operation It will be needed for high fi re operation testing. 1. Connect a manometer or Magnehelic gauge with the pressure side to the manifold pressure port and the other to the manifold Verify high fi re operation reference port.
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M 6. If CO and pressure signal are correct, allow the boiler to reach CHECKING & ADJUSTMENTS steady state and verify supply gas pressure and check input rates as explained in the Gas Supply Piping section.
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M If the gas pressure is above the limit in the table below, Pilot adjustment a lock-up style gas pressure regulator suitable for dead- 1. The pilot pressure has been factory set at 3 inches w.c., and end service, (such as an Equimeter or Fisher) must be shouldn't need adjustment.
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M 3. Remove the front jacket panel and combustion chamber door. MAINTENANCE 4. Inspect the inside and outside of the heat exchanger Disconnect electrical power and close the manual gas for signs of damage, sooting or corrosion.
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M 6. Replace the pipe plugs using a suitable thread sealant on each one. Figure 21 Main Burner Flame 7. Sagging or distorted heat exchanger tubes are an indication of low water fl ow through the system.
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M Figure 23 Futera XLF pressure sensor hose routing...
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M REPAIR PARTS Figure 24 Exploded view...
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M REPAIR PARTS (CONTINUED) Figure 25 Figure 20 – Electrical components...
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M REPAIR PARTS (CONTINUED) Model Size with item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Top/Bottom X Profi le 04-0524 Middle X Profi le 04-0526 Top Y Profi le...
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M REPAIR PARTS (CONTINUED) Model Size with item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Manifold/Orifi ce Mounting Plate (Forward) 03-3734 03-3721 Manifold/Orifi ce Mounting Plate (Rear)
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M REPAIR PARTS (CONTINUED) Model Size with item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Combustion Chamber Rear/Side Panel 70-3566 70-3567 70-3568 70-3569...
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M REPAIR PARTS (CONTINUED) Model Size with item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Frequency Drive 15-0230 Flame Safeguard, RM7895C 16-0024R Spark Ignitor 16-0008...
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M REPAIR PARTS (CONTINUED) Model Size with item Quantities Below Ref # Name of Part Part # 2500 3000 3500 4000 Control Box Panel 70-3609 Collar Fan Transition 01-0201S Gasket 06-0004...
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M START-UP REPORT DATE: JOB NAME: TECHNICIAN: LOCATION: COMPANY: MODEL: PHONE NUMBER: SERIAL #: PRE-STARTUP CHECK LIST ❑ NO VISIBLE DAMAGE TO UNIT ❑ INLET AIR FILTER INSTALLED AND CLEAN ❑...
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Finned copper tube gas boilers & water heaters – Boiler Manual & B l M COMBUSTION ANALYSIS MINIMUM FIRING RATE 100% FIRING RATE GAS PRESSURE AT ELBOW TEST PORT INCHES W.C. INCHES W.C. CO (PPM) NET STACK TEMPERATURE PRESSURE SIGNAL (Ps) INCHES W.C.
Finned copper tube gas boilers & water heaters – Boiler Manual & B l M NOTICE! Commonwealth of Massachusetts Installation Requirements MACODE-3 In the Commonwealth of Massachusett s, the installation approve the installation unless, upon inspection, the must be performed by a licensed plumber or gas fi tt er. inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 1.
Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective. All other RBI supplied Boiler/Water Heater parts are warranted against defects in material and workmanship for one (1) year from date of installation or 18 months from date of shipment from RBI.
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